Note: Descriptions are shown in the official language in which they were submitted.
CA 02561476 2006-09-28
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ABSORBENT PAD WITH CLEANING CUFFS AND METHOD OF MAKING THE SAME
FIELD OF THE INVENTION
The present invention relates to an absorbent pad with cleaning cuffs
and to a method for fabricating the absorbent pad.
BACKGROUND OF THE INVENTION
Conventional floor mops comprise a handle rotatably connected to a
mop head and a disposable absorbent cleaning pad coupled to the mop head. One
side of the disposable absorbent cleaning pad is placed in direct contact with
a
s surface to be cleaned and the opposing side of the cleaning pad is coupled
to the
mop head. The absorbent pad absorbs and retains fluids, and loosens and traps
dirt particles on the cleaning surface.
Several features have been proposed for cleaning pads in order to
improve the cleaning performance of the cleaning pad in terms of particulates
~o being picked-up by the pad. For example, United States Patent Application
Publication No. 20040128786 proposes a cleaning pad that can have one or more
"free-floating" functional cuffs which can be attached to the leading edge
and/or
the trailing edge of a cleaning pad. As a cleaning pad comprising such
functional
cuffs) is wiped back and forth across a hard surface, the functional cuffs)
"flip"
~s from side to side, purportedly picking-up and trapping particulate matters.
CA 02561476 2006-09-28
_Z_
Nevertheless, there continues to be a need to further refine and
improve absorbent pads such as those that can be used with floor mops.
SUMMARY OF THE INVENTION
According to one aspect of this invention, a surface cleaning pad
s includes a pad body configured for attachment to a cleaning implement. The
surface cleaning pad also includes a cuff coupled to the pad body and
extending
along a longitudinal extent of the pad body. The cuff has an edge portion
having a
length dimension that is greater than the longitudinal extent of the pad body.
According to another aspect of the invention, a method is provided
~o for forming a surface cleaning pad. The method includes coupling a cuff
along a
longitudinal extent of a pad body. Before or after coupling the cuff to the
pad
body, an edge portion having a length dimension that is greater than the
longitudinal extent of the pad body is defined on the cuff.
BRIEF DESCRIPTION OF THE DRAWINGS
~s Exemplary embodiments of the invention will be described with
reference to the drawings, of which:
Figure 1 is a bottom view of an absorbent cleaning pad in accordance
with an exemplary embodiment of the present invention;
Figure 2 is an end view of the absorbent cleaning pad illustrated in
2o Figure 1;
Figure 3 is a bottom view of an absorbent cleaning pad in accordance
with another exemplary embodiment of the present invention;
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Figure 4 is a right side view of the absorbent cleaning pad illustrated
in Figure 3;
Figure 5 is an end view of the absorbent cleaning pad illustrated in
Figure 3;
s Figure 6 is an end view of an absorbent cleaning pad in accordance
with yet another exemplary embodiment of the present invention;
Figures 7-16 illustrate exemplary assembly and fabrication steps for
making the absorbent cleaning pad illustrated in Figure 6;
Figure 17 is an end view of an absorbent cleaning pad in accordance
~o with still another exemplary embodiment of the present invention;
Figure 18 is a top view of the absorbent cleaning pad illustrated in
Figure 17;
Figure 19 is an end view of an absorbent cleaning pad in accordance
with another exemplary embodiment of the present invention;
~s Figure 20 is a top view of the absorbent cleaning pad illustrated in
Figure 19;
Figures 21-25 illustrate exemplary assembly and fabrication steps
used to make the absorbent cleaning pad illustrated in Figures 19 and 20;
Figure 26 is an end view of an absorbent cleaning pad in accordance
zo with yet another exemplary embodiment of the present invention;
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Figure 27 is a top view of the absorbent cleaning pad illustrated in
Figure 26;
Figure 28 is a top view of an absorbent cleaning pad in accordance
with still another exemplary embodiment of the present invention;
s Figure 29 is a partial end view of the absorbent cleaning pad
illustrated in Figure 28, showing an overlapping flap portion;
Figure 30 is a right side view of an absorbent cleaning pad in
accordance with another exemplary embodiment of the present invention;
Figure 31 is a top view of an absorbent cleaning pad in accordance
io with another exemplary embodiment of the present invention;
Figures 32 through 35 are top views of absorbent cleaning pads in
accordance with additional exemplary embodiments of the present invention; and
Figures 36 through 40 are partial top views of exemplary cuff
components that can be utilized according to aspects of the present invention.
~s DETAILED DESCRIPTION OF THE INVENTION
Although the invention is illustrated and described herein with
reference to specific embodiments, the invention is not intended to be limited
to
the details shown. Rather, various modifications may be made in the details
within
the scope and range of equivalents of the claims and without departing from
the
zo invention. Also, the embodiments selected for illustration in the figures
are not
shown to scale and are not limited to the proportions shown.
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Referring to the overall structure of one exemplary embodiment,
Figures 1 and 2 illustrate an absorbent cleaning pad designated generally by
the
numeral "10". Generally, the absorbent cleaning pad 10 has a pad body formed
from an airlaid composite and having a cleansing surface configured for
cleansing
s contact with a surface to be cleaned and an opposite surface configured to
be
positioned facing a cleaning implement. The surface cleaning pad also has a
barrier adhered to and substantially covering the opposite surface of the pad
body
and a pair of dirt entrapment members adhered to the cleansing surface of the
pad
body.
~o More specifically, the exemplary absorbent cleaning pad 10 is
provided with an absorbent layer in the form of an airlaid composite 20, dirt
entrapment surfaces in the form of two lofty cuffs 25, a barrier layer 40, and
two
attachment members 45.
Each lofty cuff 25 is folded into two equal segments and positioned
~s along the length "B" of the airlaid composite 20. A single 3-D apertured
film strip
35 is sandwiched between the folded layers of each lofty cuff 25. An adhesive
30
binds both sides of the 3-D apertured film strip 35 to the inner surfaces of
the lofty
cuff 25. A portion of the width of each lofty cuff 25 is bonded to a cleaning
side 21
of the airlaid composite 20 using an adhesive 30. The lofty cuffs 25 are
positioned
ao so that the closed-face folded ends 26 face each other. The barrier layer
40 is
adhered to the backing side 22 of the airlaid composite 20 using an adhesive
30.
Two attachment members 45 are adhered to the barrier layer 40
using an adhesive 30. In this embodiment, the attachment members 45 are
composed of hook or loop material such as VELCRO loop material available from
Zs Velcro USA Inc. of Manchester, NH. The functional side of the VELCRO loop
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material faces away from the barrier layer 40. The attachment members 45 are
optionally positioned along the entire length of the barrier layer 40 and are
separated by a distance '~C" from the side edges of the barrier layer 40, as
illustrated in Figure 2.
s In functional terms, the airlaid composite 20 of the exemplary
embodiment absorbs and retains fluids and/or other matter residing on a
surface to
be cleaned. The lofty cuff 25 serves to facilitate the removal of soils from
the
surface being cleaned by contacting and trapping larger soil particles. The
lofty
cuff 25 may provide structural integrity and rigidity by being folded and
adhered to
~o itself or a single ply of lofty cuff material could be selected to provide
these
properties. The 3-D apertured film strip 35 within each cuff 25 provides
structural
integrity and improved rigidity to the lofty cuff 25 and further traps
particles from
small solid particles to those suspended in liquid. However, the use of 3-D
apertured film strip 35 within each cuff 25 is optional. The barrier layer 40
is substantially prevents fluid from passing from the airlaid composite 20 to
the mop
head or other structure to which the cleaning pad 10 may be attached. If the
cleaning pad 10 is configured to be attached to a mop head, the barrier is
configured to keep the mop head substantially free of fluid.
The attachment members 45 provide a single attachment mechanism
zo to temporarily couple the absorbent cleaning pad 10 to the mop head. In
other
words, the attachment members 45 facilitate releasable engagement of the
cleaning pad 10 to a surface of a cleaning implement. That surface may be the
bottom side surface of a mop head or another portion of a cleaning implement.
In the exemplary embodiment and still referring to Figure 1 and 2,
zs the attachment members 45 are VELCRO loop fasteners adhered to the barrier
CA 02561476 2006-09-28
_7_
layer and optionally configured to couple with hook fasteners such as a VELCRO
hook fasteners) on a bottom-side surface of a commercially available mop head.
The VELCRO loop and hook fasteners are configured to withstand the pressure
and
stress associated with typical mopping and scrubbing motions against a surface
s being cleaned. The VELCRO loop and hook fasteners substantially limit the
absorbent cleaning pad 10 from shifting, bunching, or otherwise becoming
unattached, either partially or in whole, from the mop head. The attachment
members) 45 may optionally be designed in such a way as to allow for
attachment
to multiple types of commercially available mop systems as described in
further
io detail later.
While the exemplary embodiment illustrated in Figures 1 and 2
utilizes a loop fastener for attachment to a hook fastener of another
component,
the cleaning pad is alternatively provided with a hook fastener for attachment
to a
loop fastener of another component. Also, other forms of fasteners are
~s contemplated as well, including adhesives, co-adhesives, and other known
fastening mechanisms.
Referring now to the material composition of the exemplary
embodiment, the airlaid composite 20 is a unitized body with an absorbent core
optionally composed of wood pulp and binder fibers. The binder fibers form the
zo overall structure of the airlaid composite 20, and the wood fibers provide
absorbency. The term "unitized" refers to the airlaid as being composed of one
material composite. However, the airlaid composite 20 may be composed of
multiple material layers adhered to one another.
The airlaid composite 20 is commonly fabricated using an airlaying
zs process, as disclosed in U.S. Patent No. 6,172,276, which is herein
incorporated by
CA 02561476 2006-09-28
$ _
reference in its entirety. According to U.S. Patent No. 6,172,276, airlaying
is a
process by which a fibrous non-woven layer is formed. In the airlaying
process,
bundles of small fibers, i.e. binder fibers according to the exemplary
embodiment,
are separated and entrained in an air supply and then deposited by a forming
head
s onto a forming screen in multiple stages, usually with the assistance of a
vacuum
supply. The randomly deposited fibers then are bonded to one another using,
for
example, hot air or a spray adhesive.
Additional benefits and features of an airlaid composite construction
are disclosed in U.S. Application No. 11/240,929. The disclosure of U.S.
to Application No. 11/240,929 is incorporated herein by reference in its
entirety.
Although this embodiment includes a absorbent pad body formed from an airlaid
composite, this invention is not limited to an absorbent pad body having an
airlaid
structure. Other absorbent pad body materials, structures and/or processes are
contemplated as well. For example, an absorbent core made of long polymeric
~s filaments prepared by expanding a polymer tow, disclosed in International
Publication No. WO 2004/017883, is also contemplated for use as an absorbent
pad. The disclosure of International Publication No. WO 2004/017883 is
incorporated herein by reference in its entirety.
The barrier layer 40 may be composed of a semi-pervious or
2o impervious material. The barrier layer 40 can be made of any material known
in
the art, which substantially limits the passage of fluid. Non-limiting
examples of
suitable materials include plastics such as polyethylene, polypropylene,
polyester,
and similar materials, as well as hydrophobic foams, airlaids, wetlaids, and
laminations thereof. The barrier optionally takes the form of a film, sheet,
or
zs similar substrate.
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The lofty cuff 25 material has a relatively large and open pore
structure to trap particles and is configured to be flexible, sustain multiple
uses and
resist tearing or deformation. The lofty cuff 25 may optionally be composed of
apertured polyethylene or polypropylene films, foams, airlaids, wetlaids, or
s laminations and combinations thereof. The lofty cuff 25 component may be
either
hydrophilic or hydrophobic.
The attachment member 45 may be composed of any structure or
material providing an attachment mechanism to a cleaning implement such as a
commercial mop head. Some examples include hook and loop fasteners,
~o adhesives, cohesives, snap-in structures, magnetic elements or any other
attachment mechanism commonly known in the art. These materials may
optionally have elastic functionality.
The 3-D apertured film strip 35 may optionally be composed of
polyethylene or polypropylene films. The adhesive 30 of the exemplary
is embodiment may be composed of any material sufficient to provide a bond
between the absorbent cleaning pad components. In the exemplary embodiment
and by way of non-limiting example, one exemplary adhesive is manufactured by
H.B. Fuller Company of St. Paul, MN, e.g., Part Number 1696. However, one
skilled in the art will recognize that other types of adhesive and other
fastener
zo mechanisms are suitable for this application.
Referring to the size of the exemplary embodiment components as
illustrated in Figures 1 and 2, the width "A" of the airlaid composite 20 may
be any
dimension sufficient to cover all or a portion of the width of a surface of a
cleaning
implement, such as a mop head for example. For the purposes of illustration
only,
as the width "A" may be about 5.7 inches. The length "B" of the airlaid
composite 20,
CA 02561476 2006-09-28
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as illustrated in Figure 1, may be any dimension sufficient to cover all or a
portion
of the length of the cleaning implement. For the purposes of illustration
only, the
length "B" may be about 11.6 inches.
The thickness "E" of the airlaid composite 20, as illustrated in Figure
s 2, may be any dimension sufficient to absorb an appropriate volume of fluid
and
retain its structural integrity when wet. The length and width of the
attachment
member 45 may be any dimension suitable to adequately couple with another
structure such as a mop head. The distance "C" separating the side of the
airlaid
composite 20 and the side of the attachment member 45 may be any dimension
~o suitable to adequately couple the attachment member with the cleaning
implement. The length and width of the barrier layer 40 may be any dimension
sufficient to cover all or a portion of the airlaid composite 20.
The length of the lofty cuff 25 may be any dimension sufficient to
cover all or a portion of the length "B" of the airlaid composite 20. The
width "D"
~s of the folded lofty cuff 25 may be any dimension sufficient to cover a
portion of the
width "A" of the airlaid composite 20. The width "D" should be small enough to
provide adequate surface area for the airlaid composite 20 and large enough to
provide an adequate scrubbing surface area to remove particles from the
cleaning
surface.
zo Similar to the absorbent cleaning pad embodiment illustrated in
Figures 1 and 2, an exemplary embodiment of an absorbent cleaning pad 110 is
shown in Figures 3, 4 and 5. The absorbent cleaning pad 110 is provided with
an
airlaid composite 120, two lofty cuffs 125, a barrier layer 140, and two
attachment
members 145. The absorbent cleaning pad 110 is additionally provided with
Super
2s Absorbent Particles (SAP) 150 dispersed throughout at least a discrete zone
of the
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airlaid composite 120. In other words, the SAP 150 may be "zoned" as in the
embodiment shown in Figure 3. Alternatively the SAP 150 may be dispersed
evenly throughout the body of the airlaid composite 120.
Resulting from the addition of SAP 150, the barrier layer 140
s illustrated in Figures 3, 4 and 5 is especially advantageous. To prevent the
escapement of the zoned SAP 150 during usage, handling, or shipping of the
cleaning pad 110, the barrier layer 140 is folded over the two width-wise
sides or
edges 124 of the airlaid composite 120. As illustrated in Figure 4, the folded
sides
141 of the barrier layer 140 are adhered to the airlaid composite 120, using
an
~o adhesive 130.
The SAP 150 in this embodiment is concentrated in the center of the
width of the airlaid composite 120 designated by dimension "F", and is
isolated
from the open and exposed length-wise sides 123. The SAP 150 is substantially
concentrated in the center of the width of the airlaid composite 120 to
prevent the
~s SAP 150 from escaping out of the exposed length-wise sides 123 of the
airlaid
composite 120. Though not illustrated, it is also envisioned that the SAP 150
may
be concentrated in the center of the width "A1" and the length "B1" of the
airlaid
composite 120, thereby isolating SAP 150 from the entire periphery of the
airlaid
composite 120. In such case, the barrier layer 140 is not required to cover
the
zo length-wise sides 123 or the width-wise sides 124 to prevent the escapement
of
SAP 150 along the periphery of the airlaid composite 120.
Additional benefits and features of a "zoned" SAP construction are
disclosed in U.S. Application No. 11/240,726. The disclosure of U.S.
Application
No. 11/240,726 is incorporated herein by reference in its entirety.
Additional,
zs optional features of absorbent cleaning pads are also disclosed in U.S.
Application
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No. 11/241,138 and U.S. Application No. 11/240,949, the disclosures of which
are
incorporated herein by reference in their entirety.
Similar to the absorbent cleaning pad embodiment illustrated in
Figures 3, 4 and 5, the exemplary embodiment of an absorbent cleaning pad 210
s shown in Figure 6 is provided with an airlaid composite 220, two lofty cuffs
225, a
barrier layer 240, two attachment members 245, and super absorbent particles
(SAP) 250. In this exemplary embodiment, the Super Absorbent Particles (SAP)
250 are dispersed throughout the entire airlaid composite 220. Accordingly, to
reduce or prevent the escapement of SAP 250 from the exposed sides of the
airlaid
io composite 220, the barrier layer 240 is especially advantageous. The
barrier layer
240 is folded over the length-wise and the width-wise sides of the airlaid
composite
220 to prevent the SAP 250 from escaping along the periphery of the airlaid
composite 220.
Exemplary steps used to fabricate the embodiment of cleaning pad
~s 210 shown in Figure 6 are illustrated in Figures 7-16. Many of the
following steps
illustrated in Figures 7-16 are also relevant to the fabrication of the prior
exemplary embodiments illustrated in Figures 1-5. As illustrated in Figure 7,
the
material used to form lofty cuff 225 is unwound and cut (designated by the
triangle
symbol) to a predetermined length and width. An adhesive 230 is then applied
to
zo a single side of the lofty cuff 225. The lofty cuff 225 is folded over
itself,
maintaining the adhesive 230 on the interior of the fold, as illustrated in
Figure 8.
A portion of the width of the lofty cuff 225 is adhered to the airlaid
composite 220 using an adhesive 230, as illustrated in Figure 9. An adhesive
230
is then applied to the barrier side 222 of the airlaid composite 220, before
the
2s barrier side 222 is centered and applied to the sheet used to form barrier
layer
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240, as illustrated in Figure 10. At this stage, a plurality of airlaid
composites 220
are centered and applied to the sheet forming barrier layer 240, and the
airlaid
composites 220 are separated by a distance "G", also illustrated in Figure 10.
An adhesive 230 is applied to a single side of a "cut-and-place"
s barrier layer 260 (Figure 11) that is cut to a predetermined length and
width. The
width "H" of the cut-and-place barrier layer 260 may optionally be smaller
than the
width "J" of the barrier layer 240. The adhesive side of the cut-and-place
barrier
layer 260 is centered and applied over the width-wise ends of adjacent airlaid
composites 220, as illustrated in Figure 11. The adhesive 230 on the underside
of
io the cut-and-place barrier layer 260 bonds the cut-and-place barrier layer
260 to
the airlaid composite 220 and the sheet forming barrier layer 240. In other
words,
the cut-and-place barrier layer 260 traverses the gap "G" between two adjacent
airlaid composites 220 and overlaps the width-wise ends of the airlaid
composites
220.
Is Referring now to Figure 12, the material forming attachment
member 245 is unwound and cut (designated by the triangle symbol) to a
predetermined length and width, as illustrated schematically in Figure 12. An
adhesive 230 is then applied to the non-functional side of the attachment
member
245, as illustrated in Figure 13. The non-functional, adhesive side of the
zo attachment member 245 is applied to the barrier layer 240, as illustrated
in Figure
14. The free ends of the barrier layer 240 extending along the length of the
airlaid
composite 220 are each folded over and adhered to the cut-and-place barrier
layer
260 and the lofty cuff 225, as illustrated in Figure 15. The barrier layer 240
partially overlaps the lofty cuffs 225, thereby encapsulating a portion of the
lofty
zs cuffs 225. The absorbent cleaning pads 210 are finally cut and separated
from one
another, as illustrated in Figure 16.
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Similar to the absorbent cleaning pad embodiment illustrated in
Figure 6, the exemplary embodiment of an absorbent cleaning pad 310
illustrated
in Figures 17 and 18 is provided with an airlaid composite 320, two lofty
cuffs 325,
a barrier layer 340, and two attachment member strips 345. In this exemplary
s embodiment, the airlaid composite 320 does not include Super Absorbent
Particles
(SAP), and the periphery of the airlaid composite 320 need not be sealed.
However, it is envisioned that SAP is optionally concentrated in the center of
the
airlaid composite 320, to prevent SAP from escaping from the airlaid
composite.
The barrier layer 340 differs from the barrier layer illustrated in the
io previous exemplary embodiment. The barrier layer 340 of this exemplary
embodiment serves two purposes, i.e. preventing fluid from contacting the
cleaning
implement to which it is attached and providing an attachment mechanism to
fasten the absorbent cleaning pad 310 to the cleaning implement.
The exemplary embodiment illustrated in Figures 17 and 18 provides
is attachment members 345 (e.g., loop strips) configured to couple with an
attachment members) on the underside of a cleaning implement such as a mop
head (not shown). By way of non-limiting example, the attachment members 345
may be VELCRO loop strips and the attachment members on the underside of the
mop head may be VELCRO hook strips, or visa versa.
2o In addition to the attachment mechanism provided by the
attachment members 345, the exemplary embodiment shown in Figures 17 and 18
provides a secondary mop head attachment mechanism. The barrier layer forms
two tab portions 355 that may be inserted into retaining structures of an
cleaning
implement, such as the ones described in U.S. Pat. No. 6,305,046. However, one
zs skilled in the art will understand that a wide variety of other types of
retaining
CA 02561476 2006-09-28
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structures are suitable to retain an absorbent cleaning pad and provide the
same
benefits.
The retaining means located on the top surface of a cleaning
implement such as a mop head are suitable for mechanically engaging and
s retaining a sheet of material incorporated with or attached to an absorbent
cleaning pad. Non-limiting examples of retaining means located on the top
surface
of a mop head include clamps, clips, mechanical fasteners such as hook or loop
fasteners, pins and the like such as the ones described in U.S. Pat. No.
4,991,250
and U.S. Pat. No. 3,698,030. One skilled in the art will also understand that
the
~o previously described retaining means can also be located on the sides or
other
surfaces of a mop head and still provide the same benefits.
Referring still to Figures 17 and 18, the barrier layer 340 is adhered
to the barrier side 324 of the airlaid composite 320 using an adhesive 330.
Both
side edges of the barrier layer 340 are folded a first time forming two wing
portions
~s 356. A portion of each wing portion 356 is adhered to the barrier layer 340
using
an adhesive 330. The barrier layer 340 is folded a second time to form four
tab
portions 355, as illustrated in Figures 17 and 18. The tab portions 355 are
adhered
to the wing portions 356 using an adhesive or cohesive strip 330. The four tab
portions 355 are free to separate from the airlaid composite 320, as
illustrated by
zo the dotted line segment in Figure 17. The tab portions 355 are configured
to insert
into retaining structures on the top or side of a mop head.
Referring now to Figures 19 and 20, similar to the absorbent
cleaning pad embodiment illustrated in Figure 6, the exemplary embodiment of
an
absorbent cleaning pad 410 is provided with an airlaid composite 420, two
lofty
zs cuffs 425, a barrier layer 440, Super Absorbent Particles (SAP) 450
dispersed
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throughout the airlaid composite 420, and two attachment members 445
configured to couple with a portion of a cleaning implement such as a mop
head.
In this exemplary embodiment, the SAP 450 are dispersed
throughout the entire airlaid composite 420. Similar to the embodiment
illustrated
s in Figure 6, the barrier layer 440 is folded over the length-wise sides of
the airlaid
composite 420 to prevent the SAP 450 from escaping along the longitudinal
periphery of the airlaid composite 420. The cut-and-place barrier layer 460
prevents the SAP 450 from escaping along the transverse periphery of the
airlaid
composite 420.
io In addition to the mop head attachment mechanism provided by the
attachment members 445, this exemplary embodiment provides a secondary
means for attachment. The exemplary embodiment illustrated in Figures 19 and
20 is provided with four flap portions 470. The tab portions 470 are free to
separate from the airlaid composite 420, as illustrated by the dotted line
segment
is in Figure 19. The four flap portions 470 can be inserted into retaining
structures
positioned on the top or side of a mop head, such as the ones described in
U.S.
Pat. No. 6,305,046. However, one skilled in the art will recognize that many
other
types of retaining means are suitable to retain an absorbent cleaning pad and
provide the same benefits.
zo The flap portions 470 are configured to withstand the pressure and
stress associated with typical mopping and scrubbing motions against a surface
being cleaned and are configured to limit the absorbent cleaning pad 410 from
shifting, bunching, or otherwise becoming unattached, either partially or in
whole,
from the mop head. In this exemplary embodiment, the length °K", width
"L" and
zs thickness of the flap portions 470 may be any dimension sufficient to reach
and be
CA 02561476 2006-09-28
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adequately retained by the retaining structures disposed on the cleaning
implement.
The flap portions 470 may be composed of numerous materials.
Some examples include loop material, polyethylene or polypropylene films,
s wetlaids, wovens, nonwovens, airlaids, polyester films, or laminations and
combinations thereof. These materials may be either hydrophilic or hydrophobic
and optionally have elastic functionality.
The four flap portions 470 may be individually adhered to the barrier
layer 440 using adhesive 430. The four flap portions 470 may also provide an
~o optional attachment member 465 configured to couple with the attachment
members 445. As a non-limiting example, the attachment member 445 may be a
loop fastener and the attachment member 465 may be a hook fastener (or visa
versa), but one skilled in the art will understand that other kinds of
retaining
means are suitable to retain the flap portions 470 to the absorbent cleaning
pad
is 410.
Exemplary steps that can be used to fabricate cleaning pad 410 of
the exemplary embodiment shown in Figures 19 and 20 are illustrated in Figures
7-
16 and 21-25. Figures 7-16 were previously described with reference to another
exemplary cleaning pad embodiment. Referring now to Figure 21, material used
to
zo form each of the four attachment members 465 is unwound and cut to a
predetermined length. An adhesive 430 is then applied to the non-functional
side
of each attachment member 465. The material used to form each flap portion 470
is unwound and cut to a predetermined length and width, as illustrated in
Figure
22.
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The adhesive side of the attachment member 465 is positioned and
applied to each flap portion 470, as illustrated in Figure 23. An additional
bead of
adhesive 430 is applied to the ends of the four flap portions 470, as
illustrated in
Figure 24. The flap portions 470 are each adhered to the barrier layer 440
using
s the adhesive 430 as illustrated in Figure 25. The optional attachment
members
465 are coupled with the attachment members 445. The final fabrication steps
are
illustrated in Figures 15 and 16.
Similar to the absorbent cleaning pad embodiment illustrated in
Figures 19 and 20, the exemplary embodiment of an absorbent cleaning pad 510
~o illustrated in Figures 26 and 27 is provided with an airlaid composite 520,
two lofty
cuffs 525, a barrier layer 540 folded over the length-wise sides of the
airlaid
composite 520, and Super Absorbent Particles (SAP) 550 dispersed throughout
the
entire airlaid composite 520. The cut-and-place barrier layer 560 prevents the
SAP
550 from escaping along the transverse periphery of the airlaid composite 520.
is The exemplary embodiment of the absorbent cleaning pad provides
two means for attachment to a conventional mop head, as the perforated flap
portions 570 are capable of separating along the perforation line 574. In a
united
state, the two perforated flap portions 570 are configured to couple with the
bottom side of a mop head. In a separated state, the de-perforated flap
portions
20 570 form four flap portions 570. The separate flap portions 570 can be
inserted
into retaining structures on the top or side of a mop head, such as the ones
described in U.S. Pat. No. 6,305,046.
Two tab portions 575, optionally contiguous with the flap portions
570, are provided to ease the removal of the absorbent cleaning pad 510 from
the
2s mop head. In use, the user tugs on the two tab portions 575 to remove the
CA 02561476 2006-09-28
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absorbent cleaning pad 510 from the mop head without having to contact dirty
airlaid composite 520, dirty lofty cuff 525 or the mop head. The two tab
portions
575 extend outward from the airlaid composite 520, lofty cuff 525 and mop
head.
It is optional that only one tab portion may be provided on flap portion 570
and the
s tab portions 575 could be positioned on any longitudinal side of the
absorbent
cleaning pad 510. The tab portion 575 may also extend outward at each or one
transverse end 580 of the absorbent cleaning pad 510, if so desired.
The length "M", width "N" and thickness of the flap portions 570 may
be any dimension suitable to permit the user to remove the absorbent cleaning
pad
io 510. The flap portions 570 may be composed of many different materials.
Some
examples include loop material, polyethylene or polypropylene films, wetlaids,
wovens, nonwovens, airlaids, polyester films, or laminations and combinations
thereof. These materials may be either hydrophilic or hydrophobic and
optionally
have elastic functionality.
~s Similar to the absorbent cleaning pad embodiment illustrated in
Figures 26 and 27, the exemplary embodiment of an absorbent cleaning pad 610
illustrated in Figures 28 and 29 is provided with an airlaid composite, two
lofty
cuffs, a barrier layer folded over the length-wise and the width-wise sides of
the
airlaid composite, Super Absorbent Particles (SAP) dispersed throughout the
entire
zo airlaid composite, and two attachment members 645 configured to couple with
a
mop head 680.
In addition to the mop head attachment mechanism provided by the
attachment members 645, this exemplary embodiment provides a secondary
means for attachment. The four overlapping flap portions 670 are configured to
zs engage a mop head 680. In use, the flap portions 670 wrap around the mop
head
CA 02561476 2006-09-28
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680 and attach to each other, thereby coupling the absorbent cleaning pad 610
to
the mop head, as illustrated in Figure 29. The flap portions 670 may be
composed
of VELCRO fasteners, or any other material capable of coupling one flap
portion
670 to another.
s A third attachment member 645 adhered to the barrier layer 640 is
optionally provided to couple with the mop head to further limit the absorbent
cleaning pad 610 from shifting, bunching, or otherwise becoming unattached,
either partially or in whole, from the mop head.
Similar to the absorbent cleaning pad embodiment illustrated in
~o Figures 19 and 20, an exemplary embodiment of an absorbent cleaning pad 710
illustrated in Figure 30 is additionally provided with an extendable tab
portion 770.
The extendable tab portion 770 has a "Z" shape when viewed from the side and
is
configured to unfold and extend in the indicated direction. The extended tab
portion 770 unfolds to provide a greater distance between the user and the
dirty
~s cleaning pad and mop head. The extendable tab portions 770 could optionally
be
positioned on any side of the absorbent cleaning pad 710.
In use, the extendable tab portion 770 is stored in a Z-shape
position as shown to avoid contact with the dirty cleaning surface. To
separate the
absorbent cleaning pad 710 from the mop head, the user pulls and extends the
tab
Zo portion 770 until the absorbent cleaning pad 710 separates from the mop
head.
Similar to the absorbent cleaning pad embodiment illustrated in
Figures 26 and 27, an exemplary embodiment of an absorbent cleaning pad 810
illustrated in Figure 31 is additionally provided with a mechanism for
engaging the
hand of a user such that the cleaning pad can be used, without the need for a
zs cleaning implement, for hand-cleaning a surface. In this embodiment, the
cleaning
CA 02561476 2006-09-28
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pad 810 is provided with a hand strap 880, for example. The material used to
form
hand strap 880 is optionally elastic, though a wide variety of materials can
be
used.
The absorbent cleaning pad 810 also provides perforated flap
s portions 870 that can be used to couple with a top or bottom side of a mop
head.
In this manner, the absorbent cleaning pad 810 is similar to several
embodiments
described previously.
The elastic hand strap 880 is configured to permit the user to
operate the absorbent cleaning pad 810 independent from a cleaning implement
io such as a mop. The elastic hand strap 880 provided on the absorbent
cleaning pad
810 may be useful for cleaning any small, delicate, or non-planar surface that
a
mop head can not clean or is unable to access.
The elastic hand strap 880 may be composed of any elastic material
flexible enough to stretch around a child and an adult-sized hand and rigid
enough
~s to firmly grip a child and an adult-sized hand. In another embodiment (not
shown), the perforated flap portions 870 themselves are optionally composed of
an
elastic material to provide a hand strap to permit the user to operate the
absorbent
cleaning pad 810 independent from a mop. In such an embodiment, the hand
strap 880 can be eliminated.
zo Referring generally to Figs. 32 to 40, additional embodiments of a
surface cleaning pad will be described. According to these embodiments, a
surface
cleaning pad is configured for attachment to a cleaning implement and includes
a
pad body and a cuff (or cuffs) coupled to the pad body. The cuffs extend along
a
longitudinal extent of the pad body, wherein the cuff has an edge portion
having a
Zs length dimension that is greater than the longitudinal extent of the pad
body. The
CA 02561476 2006-09-28
_22_
longitudinal extent of the pad body may be equal to or less than the entire
end-to-
end length of the pad body. It should be understood that the longitudinal
extent of
the pad body represents the straight length of the cuff coupled to the pad
body.
Optionally, the width of the cuff component may be narrow, with
s respect to the previous cuff embodiments, thereby increasing the overall
available
absorbent cleaning surface of the pad body. For example, and according to one
embodiment, the cuffs for an absorbent pad can be formed from a 60mm wide
material whereby the resulting width of each cuff is about 30mm.
Also, by virtue of the increased cuff edge (provided by having an
~o edge length dimension that is larger than the longitudinal extent of the
pad body to
which it is coupled), the cuff has a greater potential to grab and trap more
dirt
than a cuff with a shorter edge. A cuff having a relatively shorter edge is
illustrated in Figure 3, for example.
The edge portion of the cuff is optionally curved to maintain the
is length dimension larger than the longitudinal extent of the pad body, and
the edge
portion can have a wave form extending along the cuff edge. Optionally, the
wave
form comprises a sinusoidal wave.
In another embodiment, the edge portion of the cuff is slit in
multiple locations to maintain the length dimension larger than the
longitudinal
zo extent to which the cuff is coupled to the pad body. The slits can be
substantially
evenly spaced. At least some of the slits can be oriented transverse to the
longitudinal extent of the pad body, either oriented substantially
perpendicular to
the longitudinal extent of the pad body, at an acute angle with respect to the
longitudinal extent of the pad body, or in some other configuration. For
example,
zs at least some of the slits can be oriented at an angle between about 30 and
about
CA 02561476 2006-09-28
-23-
60 degrees with respect to the longitudinal extent of the pad body. An angle
of
about 45 degrees is optionally selected.
In other embodiments, the cuff can include a repeating pattern of
slits oriented at an acute angle with respect to the longitudinal extent of
the pad
s body and slits oriented substantially perpendicular with respect to the
longitudinal
extent of the pad body. Also, at least some of the slits along the edge
portion of
the cuff can be oriented generally toward an end of the pad body while at
least
some of the slits are oriented generally toward an opposite end of the pad
body.
To fabricate such embodiments of a surface cleaning pad, a cuff that
~o is optionally formed from a high loft material is coupled along a
longitudinal extent
of a pad body, and an edge portion having a length dimension that is larger
than
the longitudinal extent to which the cuff is coupled to the pad body is
defined on
the cuff. The step of coupling the cuff to the pad body is preferably
performed
after the step of defining the edge portion on the cuff, but the coupling step
may
is be performed before the defining step.
For embodiments in which a wave form such as a sinusoidal wave is
provided along the edge portion of the cuff, the wavy pattern may help to grab
and
trap additional dirt as compared to a cuff having a straight line cut.
The embodiments such as those shown in Figures 32 through 40 are
Zo advantageous in that they may require less overall use of a cuff material
(e.g., a
narrower width). Also, such embodiments make it possible to optimize or
maximize the surface area of the pad body that is available for floor or
cleaning
surface contact. Additionally, the greater length of the edge of the cuff
(e.g.,
provided by the wave form or slits or other features) provides a potential for
CA 02561476 2006-09-28
-24-
improved and faster cleaning. Also, the improved cuff configuration is better
suited
for the entrapment of common household dirt such as hair and fur.
Referring specifically to the cleaning pad embodiment illustrated in
Figure 32, the absorbent cleaning pad 1010 includes a pair of cuffs 1025, the
ends
s of which are adhered to and positioned beneath opposing cut-and-place
barrier
layers 1024. The cuffs 1025 are therefore constrained with respect to the pad
body
such as airlaid 1020 at the outward edges of the cuffs 1025 and the terminal
ends
of the cuffs 1025 proximal to the sides 1024 of cleaning pad 1010.
Each of the cuffs 1025 includes an edge portion 1012 facing inwardly
io away from the long side edge of the absorbent cleaning pad 1010. Each edge
portion 1012 includes a curve 1014, which in this particular embodiment is a
sinusoidal wave that extends substantially from one end of the cuff 1025 to
the
other. As is apparent from Figure 32, the length dimension (i.e. edge length)
of
the edge portion 1012 is greater than the longitudinal extent (i.e. length of
the
~s long side edge) to which the cuff 1025 is coupled to the pad body 1020. Put
differently, the length of the edge portion 1012, if straightened, would
extend
farther than the straight length dimension of the cuff 1025.
Referring to the embodiment illustrated in Figure 33, an absorbent
cleaning pad 1110 also includes cut-and-place barrier layers 1124 and a pair
of
2o cuffs 1125 extending therebetween. Each of the cuffs, like those
illustrated in
Figure 32, include a series of curves 1114 extending along the length of the
cuffs
1125.
Unlike the absorbent cleaning pad 1010 illustrated in Figure 32, the
cuffs 1125 of the absorbent cleaning pad 1110 further include a series of
slits 1116
is formed along the edge portion 1112, and along the curves 1114, thereby
further
CA 02561476 2006-09-28
-25-
increasing the length dimension of the edge portion as compared to the
longitudinal extent to which the cuff 1125 is coupled to the pad body 1120. In
other words, the length of the slits 1116, when combined with the length of
the
combined curves 1114 of the edge portion 1112 are substantially longer than
the
s longitudinal extent to which the cuffs 1125 are attached to or otherwise
positioned
adjacent the pad body 1120.
Referring now to Figure 34, the absorbent cleaning pad 1210
includes cut-and-place barrier layers 1224 positioned on opposing side of the
pad
and a pair of cuffs 1225 extending therebetween. Like the absorbent cleaning
pad
~0 1110 shown in Figure 33, the absorbent cleaning pad 1210 includes a series
of slits
1216 spaced along the length of the cuffs 1224. Unlike the absorbent cleaning
pad
1110, however, absorbent cleaning pad 1210 has a substantially straight edge
1214 along edge portion 1212 of each cuff 1225. Again, because of the edges
formed by slits 1216, the length dimension of the edge along the edge portion
~s 1212 is greater than the longitudinal extent to which the cuffs 1225 are
attached to
the pad body 1220. This larger length is accomplished by the definition of
slits
1216 in the cuffs 1225 even without defining curves, such as curves 1114 of
the
cuffs 1125 illustrated in Figure 33.
Referring now to Figure 35, the absorbent cleaning pad 1310
2o includes cut-and-place barrier layers 1324 positioned on opposing sides of
the pad
and a pair of cuffs 1325 extending therebetween. Similar to other embodiments,
the edge portion 1312 includes a substantially straight edge 1314 and slits
1316.
Unlike the prior embodiments, however, the slits are provided in a orientation
that
is transverse to the lengthwise dimension of the pad 1310. While a wide
variety of
as angles can be selected, the angle of slit 1316 with respect to the length
dimension
of the pad is between about 30 and 60 degrees, and optionally about 45
degrees.
CA 02561476 2006-09-28
-26-
The slits 1316 on opposed cuffs 1325 are optionally oriented in the same or
opposite directions as compared to one another. As is illustrated in Figure
35, for
example, each of the slits 1316 on one cuff 1325 can be oriented in
substantially
the same direction (e.g., parallel to one another).
s Referring now to Figures 36-40, a wide variety of geometric
configurations are available for the slits 1316 provided in the cuffs 1325 of
the
absorbent pad 1310. For example, and for purposes of illustration only, the
slits
can be substantially perpendicular to the length of the cuffs and grouped in
pairs,
such as slits 1316a shown in Figure 36. Furthermore, the slits may be oriented
at
io acute, alternating angles, such as slits 1316b shown in Figure 37. The
slits may be
patterned in alternating perpendicular and angled directions, such as slits
1316c
and 1316d illustrated in Figures 38 and 39, respectively. The slits may also
be
grouped and patterned in opposing diagonal or angled directions, such as slits
1316e shown in Figure 40.
is While a variety of embodiments of absorbent cleaning pads have
been selected for illustration in Figures 32 through 35, it will be recognized
that a
wide variety of configurations are available for cuffs having an edge portion
with a
length dimension that is larger than the corresponding longitudinal extent of
the
pad body. This includes the option to attach more than a pair of cuffs to the
zo absorbent pad, which could each have different slit geometry if so desired.
For
example, a third cuff is optionally oriented along the length of the pad body
and in
a central region of the pad body between a spaced pair of cuffs.
Alternatively, it is
contemplated that only one cuff is provided. Also, while a variety of slit
configurations are illustrated in Figures 36 through 40 for absorbent cleaning
pads
2s having slits in a cuffs, it will be recognized that a wide variety of
configurations can
be employed.
CA 02561476 2006-09-28
Although the invention is illustrated and described herein with
reference to specific embodiments, the invention is not intended to be limited
to
the details shown. Rather, various modifications may be made in the details
within
the scope and range of equivalents of the claims and without departing from
the
s invention. Also, the embodiments selected for illustration in the figures
are not
shown to scale and are not limited to the proportions shown.
